Lincoln Electric Ranger 250 LPG Operating instructions

Brand: Lincoln Electric

Model: Ranger 250 LPG

Category: Welding System

Type: Operating instructions

Ranger 250 LPG

OPERATOR’S MANUAL

IM829-A

May, 2005

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However, your

overall safety can be increased by

proper installation ... and thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT READING THIS

MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED

THROUGHOUT. And, most

importantly, think before you act

and be careful.

For use with machines having Code Numbers:

11078, 11272

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

NRTL/C

This manual covers equipment which is no

longer in production by The Lincoln Electric Co.

Specications and availability of optional

features may have changed.

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from vaporiz-

ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. If

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you

purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box

351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available

from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

Mar ‘95

FUMES AND GASES

can be dangerous.

5.a.Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

6.h. Also see item 1.c.

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible

de la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Mar. ‘93

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or

loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to

this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims

for material damaged in shipment must be made by the purchaser against the transportation company at the

time the shipment is received.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Machine Specifications ........................................................................................................A-2

Safety Precautions. ..............................................................................................................A-3

Location and Ventilation................................................................................................A-3

Stacking ........................................................................................................................A-3

Angle of Operation ........................................................................................................A-3

Lifting.............................................................................................................................A-3

Additional Safety Precautions .......................................................................................A-3

High Altitude Operation.................................................................................................A-3

High Temperature Operation ........................................................................................A-3

Towing...........................................................................................................................A-3

Vehicle Mounting...........................................................................................................A-4

Pre-Operation Engine Service..............................................................................................A-4

Fuel ...............................................................................................................................A-4

Oil..................................................................................................................................A-5

Engine Coolant..............................................................................................................A-5

Battery Connections......................................................................................................A-5

Muffler Outlet Pipe ........................................................................................................A-5

Spark Arrester...............................................................................................................A-5

High Frequency Generators for TIG Applications .........................................................A-5

Remote Control.............................................................................................................A-5

Electrical Connections..........................................................................................................A-6

Machine Grounding.......................................................................................................A-6

Welding Terminals ........................................................................................................A-6

Welding Output Cables .................................................................................................A-6

Cable Installation...........................................................................................................A-6

Auxiliary Power Receptacles and Plugs...............................................................................A-7

Standby Power Connections................................................................................................A-7

Premises Wiring...................................................................................................................A-8

Connection of Lincoln Electric Wire Feeders .......................................................A-9 thru A-10

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ..............................................................................................................B-1

General Description..............................................................................................................B-1

Design Features...................................................................................................................B-1

Engine Operation ..........................................................................................................B-1

Welding Controls..................................................................................................................B-2

Engine Controls....................................................................................................................B-3

Starting and Stopping the Engine .................................................................................B-3

Stopping .......................................................................................................................B-4

Welding Operation................................................................................................................B-4

Duty Cycle.....................................................................................................................B-4

DC Stick Welding ..........................................................................................................B-4

Constant Current (Stick) Welding..................................................................................B-4

Pipe Welding.................................................................................................................B-4

Fuel Consumption.........................................................................................................B-4

TIG Welding ..................................................................................................................B-5

Wire Welding-CV...........................................................................................................B-5

Typical Current Ranges for Tungsten Electrodes .........................................................B-5

Arc Gouging ..................................................................................................................B-6

Auxiliary Power .............................................................................................................B-6

Simultaneous Welding and Auxiliary Power Loads.......................................................B-6

Extension Cord Recommendations...............................................................................B-6

________________________________________________________________________________

Accessories.....................................................................................................Section C

Recommended Optional Equipment.....................................................................C-1

________________________________________________________________________

vii

TABLE OF CONTENTS

Maintenance......................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance......................................................................................D-1

Engine Maintenance Components ........................................................................D-1

Engine Oil Change..........................................................................................D-2

Engine Oil Refill Capacities ............................................................................D-2

Oil Filter Change.............................................................................................D-2

Air Cleaner Service.........................................................................................D-2

Air Pre-Cleaner Service..................................................................................D-2

Air Filter Paper Element..................................................................................D-3

Spark Plug ......................................................................................................D-3

Spark Plug Service .........................................................................................D-3

Engine Adjustment..........................................................................................D-4

Battery Maintenance.......................................................................................D-4

Servicing Optional Spark Arrestor...................................................................D-4

Welder / Generator Maintenance ........................................................................D-5

Storage ...........................................................................................................D-5

Cleaning..........................................................................................................D-5

Brush Removal and Replacement..................................................................D-5

GFCI Receptacle Testing and Setting Procedure...........................................D-5

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Troubleshooting Guide..........................................................................................E-3

Troubleshooting Guide..........................................................................................E-4

Troubleshooting Guide ..........................................................................................E-5

________________________________________________________________________

Diagrams & Dimension Print..........................................................................Section F

________________________________________________________________________

Parts List ......................................................................................................P489 Series

________________________________________________________________________

Make/Model Description Horsepower Operating

Displacement

cu. in.(cu. cm)

Starting Capacities

@ 3600 RPM SPEED Bore x Stroke

in.(mm)

System

RANGER 250 LPG

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to

rated capacity. When welding, available auxiliary power will be reduced.

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS - RANGER 250 LPG ( K2336-1)

INPUT - LPG ENGINE

RATED OUTPUT @ 104°F(40C°) - WELDER

HEIGHT WIDTH DEPTH WEIGHT

30.00** in. 21.50 in. 42.25 in.

762.0 mm 546.0 mm 1073.0 mm 482 lbs. (218kg.)

**Top of enclosure, add 6.0” (152mm) for exhaust.

LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR

Full Pressure Hydraulic- (Kohler) LPG regulator and Mechanical Governor

with Full Flow Filter vaporizer

5% Regulation (Kohler)

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Top outlet Shutdown on low oil

Dual Element Automatic Idler can be rotated. Made from pressure.

long life, aluminized steel.

RATED OUTPUT @ 104°F(40C°) - GENERATOR

Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM

CC STICK & PIPE DC Output 28 Volts at 250 Amps 100%

STICK / PIPE Output Range 40 to 250 Amps

TIG Output Range 20 to 250 Amps 60 Volts

CV WIREDC Output 28 Volts at 250 Amps 100%

CV WIREDC Output 27 Volts at 275 Amps 60%

CV WIRE Output Range 14 to 28 volts

Auxiliary Power

9,000 Watts Peak, 8000 Watts Continuous, 60 Hz

120/240 Volts

PHYSICAL DIMENSIONS

ENGINE COMPONENTS

K2336-1

Kohler CH20

OHV

2 Cylinder

4 Cycle

Air Cooled

LPG

Engine

20 HP

High

3700RPM

Full Load

3500RPM

Low Idle

2400RPM

38 (624)

3.03x 2.64 (77x67)

12VDC Battery

and starter

Push Button

Starter

Group 58 Battery

(435 cold

crank amps)

Fuel:

LPG

Cylinder

Oil: 2.0Qts.(1.9L)

A-2

INSTALLATION

RANGER 250 LPG

A-2

MACHINE SPECIFICATIONS - RANGER 250 LPG Engine (K2336-1)

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

(2) 120VAC GFCI Two 20AMP for Two Duplex Receptacle

20AMP for Battery Charging Circuit

Duplex (5-20R)

(1) 120/240VAC Dual Voltage One 40AMP for Dual Voltage (2-pole)

15AMP for 42V Wire Feeder Power

Full KVA (14-50R)

Below code 11272 two 40AMP Below code 11272 Battery

cicuit breakers were used for Charging Circuit Breaker was

Dual Voltage 25 amps.

RECEPTACLES AND CIRCUIT BREAKERS

A-3

INSTALLATION

RANGER 250 LPG

A-3

• Lift only with equipment of ade-

quate lifting capacity.

• Be sure machine is stable

when lifting.

• Do not lift this machine using

lift bail if it is equipped with a

heavy accessory such as trailer

or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

The Ranger 250 LPG requires no adjustment for high

altitude.

HIGH TEMPERATURE OPERATION

At temperatures above 40°C, output de-rating is nec-

essary. For maximum output ratings, de-rate the

welder output 2Volts for every 10°C above 40°C.

TOWING

The recommended trailer for use with this equipment

for road, in-plant and yard towing by a vehicle

(1)

Lincoln’s K957-1. If the user adapts a non-Lincoln

trailer, the user must assume responsibility that the

method of attachment and usage does not result in a

safety hazard nor damage the welding equipment.

Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln

equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue

stress to the framework.

3. Proper placement of the equipment on the trailer to

insure stability side to side and front to back when

being moved and when standing by itself while

being operated or serviced.

4. Typical conditions of use, i.e., travel speed; rough-

ness of surface on which the trailer will be operat-

ed; environmental conditions.

5. Conformance with federal, state and local laws.

(1)

(1) Consult applicable federal, state and local laws regarding spe-

cific requirements for use on public highways.

SAFETY PRECAUTIONS

• Only qualified personnel should install,

use, or service this equipment.

LOCATION AND VENTILATION

The welder should be located to provide an unrestrict-

ed flow of clean, cool air to the cooling air inlets and to

avoid restricting the cooling air outlets. Also, locate

the welder so that the engine exhaust fumes are prop-

erly vented to an outside area.

STACKING

Ranger 250 LPG machines cannot be stacked.

ANGLE OF OPERATION

Engines are designed to run in the level condition

which is where the optimum performance is achieved.

The maximum angle of continuous operation is 15

degrees in any direction. If the engine is to be operat-

ed at an angle, provisions must be made for checking

and maintaining the oil level at the normal (FULL) oil

capacity in the crankcase.

LIFTING

The RANGER 250 LPG weighs approximately 482

lbs. (218Kg.). A lift bail is mounted to the machine and

should always be used when lifting the machine.

Do not attempt to use this equipment until you

have thoroughly read the engine manufacturer’s

manual supplied with your welder. It includes

important safety precautions, detailed engine

starting, operating and maintenance instructions,

and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

• See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

WARNING

A-4

INSTALLATION

RANGER 250 LPG

A-4

Be certain that the cylinder valve is CLOSED before

attempting to attach the fuel supply hose coupler to

the cylinder. Connect the coupler to the fuel cylinder

and tighten by hand.

___________________________________________

After connecting the fuel supply to the supply cylinder,

open the valve on the fuel cylinder and leak test by

brushing a 50/50 soap and water solution on to the fol-

lowing connections:

• Both ends of the fuel hose where it enters the metal connector.

• The threaded fitting on the end of fuel hose attached to the

Ranger 250 LPG fuel shut off solenoid.

• The fuel hose coupler and the connection to the cylinder valve.

• The stem of the cylinder valve and where the valve is attached

to the top of the cylinder.

• All other fittings on top of the fuel cylinder.

If growing bubbles appear, there is a leak. Re-tighten

connection or replace defective component. Retest to

make sure that there is no leak.

Leak test must be performed each time the fuel cylin-

der is replaced.

Always close the cylinder valve when the machine is

not being used.

The specification for aluminum lift truck cylinders are

shown below:

Capacity Cylinder Weight Foot ring

LP-Gas Volume Empty Outside

(LBS.) (Cu. In.) (LBS.) Diameter

33.5 2219 22.5 9 3/8”

43.5 2873 25.5 9 3/8”

Note: The Ranger 250 LPG cannot

be used with vapor

draw LP gas cylinders such as those used for

recreation vehicles, trailers, grills, and boats.

PRE-OPERATION SERVICE

READ the engine operating and maintenance

instructions supplied with this machine.

FUEL

A lift truck type coupler is provided on the supplied

fuel line for easy hand attachment to a lift truck type

LPG fuel cylinder. The fuel cylinder must meet D.O.T.

Specification 4E-240. The valve on the fuel cylinder

must

be installed on the outlet marked “LIQUID”.

The engine will not develop full power if connected to

the vapor outlet.

LPG

fuel can cause fire or explosion.

• All leak testing must be done in a

well ventilated area free from all

potential ignition sources.

• Keep sparks and flame away from machine

and LPG supply cylinder.

• Do not expose the LPG supply cylinder to

temperatures exceeding 120°F (49°C).

• Do not weld on or near the LPG supply cylin-

der.

• Do not smoke or allow any potential ignition

sources near the LPG supply cylinder.

•

Always be certain that the LPG supply cylinder is

NOT in the welding circuit. Do not allow either

welding cable to come in contact with the supply

cylinder.

• Replace the fuel supply hose if there is

excessive abrasion, cracks or wear or if the

hose is cut.

------------------------------------------------------------------------

WARNING

CAUTION

VEHICLE MOUNTING

Improperly mounted concentrated loads may

cause unstable vehicle handling and tires or other

components to fail.

• Only transport this Equipment on serviceable

vehicles which are rated and designed for such

loads.

• Distribute, balance and secure loads so vehicle

is stable under conditions of use.

• Do not exceed maximum rated loads for compo-

nents such as suspension, axles and tires.

• Use appropriate nuts bolts and lockwashers to

attach the equipment base to the metal bed or

frame of vehicle.

• Follow vehicle manufacturer’s instructions.

------------------------------------------------------------------------

WARNING

A-5

INSTALLATION

RANGER 250 LPG

A-5

OIL

The RANGER 250 LPG is shipped with the engine

crankcase filled with high quality SAE 10W-30 oil.

Check the oil level before starting the engine. If it is

not up to the full mark on the dip stick, add oil as

required. Check the oil level every four hours of run-

ning time during the first 25 running hours. Refer to

the engine Operator’s Manual for specific oil recom-

mendations and break-in information. The oil change

interval is dependent on the quality of the oil and the

operating environment. Refer to the Engine Operator’s

Manual for the proper service and maintenance inter-

vals.

ENGINE COOLING SYSTEM

Air to cool the engine is drawn in lower set of louvers

on the case back. It is important that the intake air is

not restricted. Allow a minimum clearance of 2 feet

(0.6m) from the case back to a vertical surface.

BATTERY CONNECTION

Use caution as the electrolyte is a strong acid that

can burn skin and damage eyes.

------------------------------------------------------------------------

The RANGER 250 LPG is shipped with the negative

battery cable disconnected. Make certain that the

RUN-STOP switch is in the STOP position. Remove

the two screws from the rear battery tray using a

screwdriver or a 3/8" socket. Attach the negative bat-

tery cable to the negative battery terminal and tighten

using a 1/2" socket or wrench.

NOTE: This machine is furnished with a wet charged

battery; if unused for several months, the battery may

require a booster charge. Be careful to charge the bat-

tery with the correct polarity.

------------------------------------------------------------------------

MUFFLER OUTLET PIPE

Using the clamp provided secure the outlet pipe to the

outlet tube with the pipe positioned such that it will

direct the exhaust in the desired direction. Tighten

using a 9/16" socket or wrench.

SPARK ARRESTER

Some federal, state or local laws may require that

gasoline or diesel engines be equipped with exhaust

spark arresters when they are operated in certain

locations where unarrested sparks may present a fire

hazard. The standard muffler included with this welder

does not qualify as a spark arrester. When required

by local regulations, a suitable spark arrester, such as

the S24647 must be installed and properly main-

tained.

An incorrect spark arrester may lead to damage to

the engine or adversely affect performance.

------------------------------------------------------------------------

HIGH FREQUENCY GENERATORS FOR

TIG APPLICATIONS

The K930-2 TIG Module is suitable for use with the

RANGER 250 LPG. The RANGER 250 LPG and any

high frequency generating equipment must be proper-

ly grounded. See the K930-2 Operating Manual for

completed instructions on installation, operation, and

maintenance.

REMOTE CONTROL

The RANGER 250 LPG is equipped with a 6 pin and a

14-pin connector. The 6-pin connector is for connect-

ing the K857 or K857-1 Remote Control (optional) or

for TIG welding, the K870 foot Amptrol or the K963-3

hand Amptrol.

When in the CC-STICK, DOWNHILL PIPE, and CV-

WIRE modes or when a remote control is connected

to the 6-pin connector, the auto-sensing circuit in the

RANGER 250 LPG automatically switches the OUT-

PUT control from control at the welder to remote con-

trol .

The 14-pin connector is used to directly connect a

wire feeder or TIG Module (K930-2) control cable. In

the CV-WIRE mode, the RANGER 250 LPG auto-

sensing circuit automatically makes the RANGER 250

LPG Output Control inactive and the remote voltage

control active when the control cable is connected to

the 14 pin connector.

When in the TOUCH START TIG mode and when a

Amptrol is connected to the 6 Pin connector the OUT-

PUT dial is used to set the maximum current range of

the CURRENT CONTROL of the Amptrol.

NOTE: When a wire feeder with a built in welding volt-

age control is connected to the 14 pin connector, do

not connect anything to the 6 pin connector.

CAUTION

A-6

INSTALLATION

RANGER 250 LPG

A-6

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

Because this portable engine driven welder creates its

own power, it is not necessary to connect its frame to

an earth ground, unless the machine is connected to

premises wiring (home, shop, etc.)

To prevent dangerous electric shock, other equipment

to which this engine driven welder supplies power

must:

1) Be grounded to the frame of the welder using a

grounded type plug.

2) Be double insulated.

Do not ground the machine to a pipe that carries

explosive or combustible material.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, its

frame must be electrically bonded to the metal frame

of the vehicle. Use a #8 or larger copper wire connect-

ed between the machine grounding stud and the

frame of the vehicle. When this engine driven welder

is connected to premises wiring such as that in a

home or shop, its frame must be connected to the

system earth ground. See further connection instruc-

tions in the section entitled "Standby Power

Connections" as well as the article on grounding in the

latest U.S. National Electrical Code and the local

code.

In general, if the machine is to be grounded, it should

be connected with a #8 or larger copper wire to a solid

earth ground such as a metal water pipe going into

the ground for at least ten feet and having no insulat-

ed joints, or to the metal framework of a building

which has been effectively grounded.

The U.S. National Electrical Code lists a number of

alternate means of grounding electrical equipment. A

machine grounding stud marked with the symbol

is provided on the front of the welder.

WELDING TERMINALS

The RANGER 250 LPG is equipped with a toggle

switch for selecting "hot" welding terminals when in

the "WELD TERMINALS ON" position or "cold" weld-

ing terminals when in the "REMOTELY CON-

TROLLED" position.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work

cables to the output studs. The welding process dic-

tates the polarity of the electrode cable. These con-

nections should be checked periodically and tightened

with a 3/4" wrench.

Table A.1 lists recommended cable sizes and lengths

for rated current and duty cycle. Length refers to the

distance from the welder to the work and back to the

welder. Cable diameters are increased for long cable

lengths to reduce voltage drops.

TABLE A-1

CABLE INSTALLATION

Install the welding cables to your RANGER 250 LPG

as follows.

1. The engine must be OFF to install welding cables.

2. Remove the flanged nuts from the output terminals.

3. Connect the electrode holder and work cables to

the weld output terminals. The terminals are identi-

fied on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the

“work”) is properly connected to the work clamp and

cable.

6. Check and tighten the connections periodically.

• Loose connections will cause the output terminals

to overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output

terminal connection. Keep the cables isolated

and separate from one another.

------------------------------------------------------------------------

WARNING

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-31meters)

100-150 Ft. (30-46 meters)

150-200 Ft. (46-61 meters)

Cable Size for

250 Amps

100% Duty Cycle

1 AWG (35mm

)

1 AWG (35mm

)

1/0 AWG (50mm

)

CAUTION

A-7

INSTALLATION

RANGER 250 LPG

A-7

AUXILIARY POWER RECEPTACLES

Start the engine and set the “IDLER” control switch to

the “High Idle” mode. Voltage is now correct at the

receptacles for auxiliary power. This must be done

before a tripped GFCI receptacle can be reset proper-

ly. See the MAINTENANCE section for detailed infor-

mation on testing and resetting the GFCI receptacle.

The auxiliary power of the RANGER 250 LPG con-

sists of two 20 Amp-120 VAC (5-20R)GFCI duplex

receptacles and one 50 Amp 120/240 VAC (14-50R)

receptacle. The 240 VAC receptacle can be split for

single phase 120 VAC operation.

The auxiliary power capacity is 9,000 Watts Peak,

8000 Watts Continuous of 60 Hz, single phase power.

The auxiliary power capacity rating in watts is equiva-

lent to volt-amperes at unity power factor. The max

permissible current of the 240 VAC output is 33 Amps.

The 240 VAC output can be split to provide two sepa-

rate 120 VAC outputs with a max permissible current

of 33 Amps per output to two separate 120 VAC

branch circuits (these circuits cannot be paralleled).

Output voltage is within ± 10% at all loads up to rated

capacity. All auxiliary power is protected by circuit

breakers.

The 120V auxiliary power receptacles should only be

used with three wire grounded type plugs or approved

double insulated tools with two wire plugs. The current

rating of any plug used with the system must be at

least equal to the current capacity of the associated

receptacle.

NOTE: The 240V receptacle has two 120V circuits,

but are of opposite polarities and cannot be paralleled.

STANDBY POWER CONNECTIONS

The RANGER 250 LPG is suitable for temporary,

standby or emergency power using the engine manu-

facturer’s recommended maintenance schedule.

The RANGER 250 LPG can be permanently installed

as a standby power unit for 240 VAC, 3 wire, single

phase, 33 amp service. Connections must be made

by a licensed electrician who can determine how the

120/240 VAC power can be adapted to the particular

installation and comply with all applicable electrical

codes.

1. Install the double-pole, double-throw switch

between the power company meter and the premis-

es disconnect. Switch rating must be the same or

greater than the customer’s premises disconnect

and service over current protection.

2. Take necessary steps to assure load is limited to

the capacity of the RANGER 250 LPG by installing

a 40 amp, 240 VAC double pole circuit breaker.

Maximum rated load for each leg of the 240 VAC

auxiliary is 33 amperes.

Loading above the rated output will reduce output

voltage below the allowable - 10% of rated voltage

which may damage appliances or other motor-dri-

ven equipment and may result in overheating of the

RANGER 250 LPG engine and/or alternator wind-

ings.

3. Install a 50 amp, 120/240 VAC plug (NEMA Type

14-50) to the double-pole circuit breaker using No.

6, 4 conductor cable of the desired length. (The 50

amp, 120/240 VAC plug is available in the optional

K802R plug kit or as part number T12153-9.)

4. Plug this cable into the 50 Amp, 120/240 Volt

receptacle on the RANGER 250 LPG case front.

A-8

INSTALLATION

RANGER 250 LPG

A-8

240 Volt

60 Hz.

3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL

BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

40AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW

SWITCH RATING TO BE THE SAME

AS OR GREATER THAN PREMISES

SERVICE OVERCURRENT

PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

CONNECTION OF RANGER 250 LPG TO PREMISES

WARNING

• Only a licensed, certified, trained electrician should install the machine to a premises or residential

electrical system. Be certain that:

•The installation complies with the National Electrical Code and all other applicable electrical codes.

•The premises is isolated and no feedback into the utility system can occur. Certain state and local

laws require the premises to be isolated before the generator is linked to the premises. Check your

state and local requirements.

•A double pole, double throw transfer switch in conjunction with the properly rated double throw cir

cuit breaker is connected between the generator power and the utility meter.

A-9

INSTALLATION

RANGER 250

A-9

CONNECTION OF LINCOLN ELEC-

TRIC WIRE FEEDERS

Connection of LN-7 or LN-8 to the RANGER 250

LPG

1. Shut the welder off.

2. Connect the LN-7 or LN-8 per instructions on the

appropriate connection diagram in Section F

3. Set the "WIRE FEEDER VOLTMETER" switch to

either "+" or "-" as required by the electrode being

used.

4. Set the "MODE" switch to the "CV WIRE " posi-

tion.

5. Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

6. Set the "WELD TERMINALS" switch to the

"REMOTELY CONTROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of LN-15 Wire Feeder to the RANGER

250 LPG

These connections instructions apply to both the LN-

15 Across-The-Arc and Control Cable models. The

LN-15 has an internal contactor and the electrode is

not energized until the gun trigger is closed. When the

gun trigger is closed the wire will begin to feed and the

welding process is started.

a. Shut the welder off.

b. For electrode Positive, connect the electrode cable

to the "+" terminal of the welder and work cable to

the "-" terminal of the welder. For electrode

Negative, connect the electrode cable "-" terminal

of the welder and work cable to the "+" terminal of

the welder.

c. Across-The-Arc Model:

Attach the single lead from the front of the LN-

15 to work using the spring clip at the end of

the lead. This is a control lead to supply cur-

rent to the wire feeder motor; it does not carry

welding current.

Control Cable Model:

Connect Control Cable between Engine

Welder and Feeder.

d. Set the MODE switch to the "CV-WIRE " position.

e. Across-The-Arc Model:

Set the "WELD TERMINALS" switch to

"WELD TERMINALS ON"

Control Cable Model:

Set the "WELD TERMINALS" switch to

"REMOTELY CONTROLLED"

f. Set the "WIRE FEEDER VOLTMETER" switch to

either "+" or "-" as required by the electrode polarity

being used.

g. Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

h. Set the "IDLE" switch to the "AUTO IDLE" position.

A-10

INSTALLATION

RANGER 250 LPG

A-10

Connection of Prince Spool Gun

to the RANGER

250 LPG

Connection of the Prince XL Spool Gun requires the

use of the K1849-1 Adapter Module.

1. Shut the Welder off.

2. For electrode Positive, connect the electrode cable

to the "+" terminal of the welder and work cable to

the "-" terminal of the welder. For electrode

Negative, connect the electrode cable "-" terminal

of the welder and work cable to the "+" terminal of

the welder.

3. Connect the Control Cable of the Spool Gun to the

Adapter Module and connect the Control Cable of

the Adapter Module to the Welder.

4. Connect the Gas Hose.

5. Set the MODE switch to the "CV-WIRE " position.

6. Set the "WELD TERMINALS" switch to "WELD

TERMINALS ON"

7. Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

8. Set the "IDLE" switch to the "High" position.

Connection of the LN-25 to the RANGER 250 LPG

The LN-25 with or without an internal contactor may be

used with the RANGER 250 LPG. See the appropriate

connection diagram in Section F.

Note: The LN-25 (K431) Remote Control Module and

(K432) Remote Cable are not recommended for use with

the RANGER 250 LPG.

1. Shut the welder off.

2. For electrode Positive, connect the electrode cable

from the LN-25 to the "+" terminal of the welder and

work cable to the "-" terminal of the welder. For elec-

trode Negative, connect the electrode cable from the

LN-25 to the "-" terminal of the welder and work cable

to the "+" terminal of the welder.

3. Attach the single lead from the front of the LN-25 to

work using the spring clip at the end of the lead. This

is a control lead to supply current to the wire feeder

motor; it does not carry welding current.

4. Set the MODE switch to the "CV-WIRE " position.

5. Set the "WELD TERMINALS" switch to "WELD TER-

MINALS ON"

6. Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

7. Set the "IDLE" switch to the "AUTO" position. When

not welding, the RANGER 250 LPG engine will be at

the low idle speed. If you are using an LN-25 with an

internal contactor, the electrode is not energized until

the gun trigger is closed.

8. When the gun trigger is closed, the current sensing

circuit will cause the RANGER 250 LPG engine to go

to the high idle speed, the wire will begin to feed and

the welding process started. When welding is

stopped, the engine will revert to low idle speed after

approximately 12 seconds unless welding is

resumed.

Connection of LN-742, K487-25 Spool Gun, and

Cobramatic

to the RANGER 250 LPG

1. Shut the welder off.

2. Connect per instructions on the appropriate con-

nection diagram in Section F.

B-1

OPERATION

RANGER 250 LPG

B-1

GENERAL DESCRIPTION

The RANGER 250 LPG is an engine powered DC

multi-process welding power source and 120 / 240

volt AC power generator. The engine drives a genera-

tor that supplies three phase power for the DC weld-

ing circuit and single phase power for the AC auxiliary

outlets. The DC welding control system uses state of

the art Chopper Technology (CT tm) for superior weld-

ing performance. The RANGER 250 LPG is not rec

ommended for pipe thawing.

DESIGN FEATURES

ENGINE OPERATION

Before Starting the Engine:

1. Be sure the machine is on a level surface.

2. Open top engine door and remove the engine oil

dipstick and wipe it with a clean cloth. Reinsert the

dipstick and check the level on the dipstick.

3. Add oil (if necessary) to bring the level up to the full

mark. Do not overfill. Close engine door.

4. See Engine Owner’s Manual for specific oil recom-

mendations.

• The combustion of LPG fuel

does produce carbon monoxide.

Although the level of CO

emis-

sion is lower than gasoline com-

bustion, the exhaust from the

Ranger 250 LPG can kill.

• Avoid breathing of vapor.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------

WARNING

SAFETY PRECAUTIONS

Read and understand this entire section before

operating your RANGER 250 LPG.

Do not attempt to use this equipment until you

have thoroughly read all operating and mainte-

nance manuals supplied with your machine. They

include important safety precautions, detailed

engine starting, operating and maintenance

instructions and parts lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts

such as output terminals or internal

wiring.

•Insulate yourself from the work and

ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or

vent exhaust outside

•Do not stack anything near the

engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open or

guards off.

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

• Only qualified personnel should operate this

equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door

closed and the side panels in place as these pro-

vide maximum protection from moving parts and

insure proper cooling air flow.

B-2

OPERATION

B-2

WELDING CONTROLS:

1. OUTPUT CONTROL: The CONTROL dial pro-

vides continuous control of the welding current or weld-

ing voltage depending on the selected welding mode.

This control is not active in the CC-STICK, DOWNHILL

PIPE, and CV-WIRE modes when a remote control or

wire feeder with remote control is connected to either

the 6 pin or 14 pin Amphenol.

2. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE

DOWNHILL PIPE

CC-STICK

TOUCH START TIG

3. ARC CONTROL :

The ARC CONTROL WIRE/STICK dial is active in the

WIRE, STICK and DOWNHILL PIPE modes, and has

different functions in these modes. This control is not

active in the TIG mode.

CC-STICK mode: In this mode, the ARC CONTROL dial

sets the short circuit current (arc-force) during stick welding

to adjust for a soft or crisp arc. Increasing the number from -

10(soft) to +10(crisp) increases the short circuit current and

prevents sticking of the electrode to the plate while welding.

This can also increase spatter. It is recommended that the

ARC CONTROL be set to the minimum number without

electrode sticking. Start with a setting at 0.

DOWNHILL PIPE MODE: In this mode, the ARC CONTROL

dial sets the short circuit current (arc force) during stick

welding to adjust for a soft or a more forceful digging arc

(crisp). Increasing the number from -10(soft) to +10(crisp)

increases the short circuit current which results in a more

forceful digging arc. Typically a forceful digging arc is pre-

ferred for root and hot passes. A softer arc is preferred for fill

and cap passes where weld puddle control and deposition

(“stacking” of iron) are key to fast travel speeds. It is recom-

mended that the ARC CONTROL be set initially at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROL

clockwise from –10 (soft) to +10 (crisp) changes the arc from

soft and washed-in to crisp and narrow. It acts as an induc-

tance control. The proper setting depends on the procedure

and operator preference. Start with a setting at 0.

RANGER 250 LPG

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Lincoln Electric Ranger 250 LPG Operating instructions

Brand: Lincoln Electric

Model: Ranger 250 LPG

Category: Welding System

Type: Operating instructions

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